Barrier Cuff for a Unitary Disposable Absorbent Article Having Intermediate Bond for Sustained Fit

ABSTRACT

Absorbent articles such as disposable diapers and disposable pant like garments are disclosed. In particular, absorbent articles such as disposable diapers and pants having an improved barrier cuff structure for improved fit are described. The placement of a barrier cuff structure having a tackdown point near the waistband of the article tends to “pull down” the waistband and may cause sagging. Intermediate tackdown bonds are disclosed to achieve the containment benefits of a barrier cuff structure without sacrificing fit characteristics of the article. The intermediate tackdown may be intermediate one or both of the longitudinal ends of the barrier cuff strip and the lateral side edges of the strip. Additionally, the relationship of forces, angles, and design characteristics of aspects of the articles and sagging are disclosed.

CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation of application Ser. No. 11/195,272,filed Aug. 2, 2005, which is incorporated herein by reference.

FIELD OF INVENTION

This invention relates to barrier cuffs on absorbent articles, such asdiapers, and more particularly to improved designs of such barrier cuffsfor improved article fit. In another aspect it relates to an improveddiaper for improved fit.

BACKGROUND OF THE INVENTION

The major function of absorbent articles, such as disposable diapers andadult incontinent briefs, is to absorb and contain body exudates. Sucharticles are thus intended to prevent body exudates from soiling,wetting, or otherwise contaminating clothing or other articles, such asbedding, that come in contact with the wearer. One common mode offailure for such products occurs when body exudates leak out of the gapsbetween the article and the wearer's leg to adjacent clothing becausethey are not immediately absorbed within the article. For example, inthe absence of a cuff or other barrier structure, urine may leak out ofthe side of the article. Additionally, loose fecal material that is noteasily absorbed by the absorbent article tends to “float” on theliquid-receiving surface and work its way past the legs of the wearer.

Contemporary absorbent articles have a topsheet, a backsheet, anabsorbent core, a barrier cuff and a gasketing cuff. The gasketing cuffproves effective generally to prevent wicking and overflow from thefluid laden article to clothing contacting the edges of the article inthat the gasketing cuff presents a fluid impermeable barrier between theedge of the article and the contacting clothing, and in addition,provides a gasketing action about the legs of the wearer. The barriercuff proves effective generally to inhibit loose fecal material orgushes of urine or liquids from soiling the wearer's clothing. Thebarrier cuff restrains the free flow of this material and provides astructure to hold such material within the article. The barrier cuffstructure typically includes at least a proximal edge that is joined tothe topsheet or other absorbent article structure and a distal edge thatis not secured to any other element, at least in the crotch region ofthe diaper, so that it may be spaced away from the topsheet.

Each barrier cuff further typically includes a spacing elastic member toelasticize the barrier cuff. The spacing elastic member is attached tothe barrier cuff in at least the crotch region of the absorbent articleand is selected so that it is placed in tension when the article isworn. The tension force in the spacing elastic member biases the barriercuff distal end away from the topsheet, thereby to form a channel forreceiving and retaining exudates.

While a barrier cuff is typically only needed in the crotch region,production methods may require the barrier cuff to extend along theentire longitudinal length (also known as the machine direction) of theabsorbent article. Absorbent articles such as diapers are typicallyformed from multiple webs of material that are joined together andsubsequently separated from the webs. Accordingly, structures such asbarrier cuffs preferably extend along the entire longitudinal length ofthe article to facilitate manufacture. To improve comfort and fit, theends of each barrier cuff are joined to the article structure (such asthe topsheet) to form front and rear closure zones, which are located inthe front and rear waist regions, respectively.

While barrier cuffs are largely effective for retaining floatingexudates within the crotch region of the absorbent article, it has beenfound that conventional barrier cuffs contribute to sagging of thearticle when worn, particularly in the front waist region.

SUMMARY OF THE INVENTION

The invention is directed to absorbent articles having a front waistregion, a back waist region, and a crotch region between the front andback waist regions. The article further has an interior surface and anexterior surface, and a longitudinal axis and a lateral axis. Thearticle has two laterally opposed, longitudinally extending barrier cuffstrips associated with the interior surface of the absorbent assembly.Each barrier cuff strip has longitudinally opposed front and back endsdisposed in the respective waist regions. Each cuff also haslongitudinally extending laterally proximal and distal edges connectingthe front and back ends. Each barrier cuff strip is joined to theinterior surface of the absorbent assembly along the proximal edge whileeach barrier cuff strip distal edge is attached to the interior surfaceof the absorbent assembly at end bonds located adjacent to the front andback ends of the barrier cuff strip. Each barrier cuff strip includes alongitudinally extending elastic gathering member attached adjacent tothe distal edge such that when allowed to relax, the elastic gatheringmember contracts and lifts the distal edge away from the interiorsurface of the absorbent assembly. Each barrier cuff strip is alsoattached to the interior surface of the absorbent assembly at adiscrete, intermediate bond located laterally between the proximal anddistal edges and longitudinally between the respective end bond and thelateral axis within one of the waist regions.

The intermediate bond of the absorbent article may be located in thefront waist region

The intermediate bond may be located approximately midway between theproximal and distal edges.

Each end bond may comprise multiple discrete bond sites arranged in arepetitive pattern and the intermediate bond is located outside thepattern.

The intermediate bonds may be joined to the absorbent core.

The barrier cuff strips and the topsheet may be formed from a samematerial piece.

The proximal edges of the barrier cuff strips may be located nearer thelongitudinal axis than the distal edges of the barrier cuff strips.Alternatively, the distal edges of the barrier cuff strips may belocated nearer the longitudinal axis than the proximal edges of thebarrier cuff strips.

The barrier cuff strips may comprise dual cuff barrier cuff strips.

The absorbent article may comprise a pair of elasticized outer cuffs.

In one embodiment, an absorbent article of the invention may comprise anabsorbent assembly having a front waist region, a back waist region, anda crotch region between the front and back waist regions. The articlemay have an interior surface and an exterior surface, and a longitudinalaxis and a lateral axis. The article may have an absorbent core disposedbetween the interior and exterior surfaces with at least a portionextending into one of the waist regions. The article may comprise twolaterally opposing, longitudinally extending barrier cuff stripsassociated with the interior surface of the absorbent assembly.

Each barrier cuff strip has longitudinally opposing front and back endsdisposed in the respective waist regions and longitudinally extending,laterally proximal and distal edges connecting the front and back ends.Each barrier cuff strip is joined to the interior surface of theabsorbent assembly along the proximal edge. Each barrier cuff stripdistal edge is attached to the interior surface of the absorbentassembly at end bonds located adjacent to the front and back ends of thebarrier cuff strip. Each barrier cuff strip includes a longitudinallyextending elastic gathering member attached adjacent to the distal edgesuch that when allowed to relax, the elastic gathering member contractsand lifts the distal edge away from the interior surface of theabsorbent assembly. Each barrier cuff strip is also joined to a portionof the absorbent assembly within one of the waist regions at a discrete,intermediate bond.

In another embodiment, an absorbent article of the invention maycomprise a front waist region, a back waist region, and a crotch regionbetween the front and back waist regions. The article may have aninterior surface and an exterior surface, and a longitudinal axis and alateral axis. The article may have two laterally opposing,longitudinally extending barrier cuff strips associated with theinterior surface of the absorbent assembly. Each barrier cuff strip mayhave longitudinally opposing front and back ends disposed in therespective waist regions. Each barrier cuff strip may havelongitudinally extending, laterally proximal and distal edges connectingthe front and back ends. The proximal edges may be located nearer thelongitudinal axis than the distal edges. Each barrier cuff strip isjoined to the interior surface of the absorbent assembly along theproximal edge, each barrier cuff strip distal edge being attached to theinterior surface of the absorbent assembly at end bonds located adjacentto the front and back ends of the barrier cuff strip. Each barrier cuffstrip includes a longitudinally extending elastic gathering memberattached adjacent to the distal edge such that when allowed to relax,the elastic gathering member contracts and lifts the distal edge awayfrom the interior surface of the absorbent assembly. Each barrier cuffstrip is also attached to the interior surface of the absorbent assemblyat a discrete, intermediate bond located laterally between the proximaland distal edges and longitudinally between the respective end bond andthe lateral axis within one of the waist regions.

BRIEF DESCRIPTION OF THE DRAWINGS

While the specification concludes with claims pointing out anddistinctly claiming the present invention, it is believed the same willbe better understood by the following drawings taken in conjunction withthe accompanying specification wherein like components are given thesame reference number.

FIG. 1 is a plan view of an absorbent article embodiment of the presentinvention having portions cut-away to reveal underlying structure;

FIG. 2 is a fragmentary sectional view taken along section line 2-2 ofFIG. 1;

FIG. 3 is a fragmentary sectional view taken along section line 3-3 ofFIG. 1;

FIG. 4 is a perspective view of the disposable diaper embodiment of FIG.1;

FIG. 5 is a fragmentary coronal view showing the diaper of FIG. 1 inplace on a wearer;

FIG. 6 is a front schematic view of a diaper as worn by a wearer;

FIG. 7 is a side schematic view of a diaper as worn by a wearer;

FIG. 8 is a plan view, in cross-section, of a diaper as worn by awearer;

FIG. 9 is a plan view of an alternative embodiment of an absorbentarticle constructed in accordance with the present invention;

FIG. 10 is a plan view of yet another alternative embodiment of anabsorbent article constructed in accordance with the present invention;

FIG. 11 is a cross-sectional view taken along section line 11-11 of FIG.10;

FIG. 12 is a fragmentary sectional view of an alternative embodiment ofa barrier cuff assembly;

FIG. 13 is a fragmentary sectional view of a further alternativeembodiment of a barrier cuff assembly;

FIG. 14 is a fragmentary sectional view of a diaper embodiment having adual cuff barrier cuff;

FIG. 15 is a plan view of another alternative embodiment of an absorbentarticle according the present invention.

DETAILED DESCRIPTION OF THE INVENTION

As used herein, the following terms have the following meanings:

“Absorbent article” refers to devices that absorb and contain liquid,and more specifically, refers to devices that are placed against or inproximity to the body of the wearer to absorb and contain the variousexudates discharged from the body.

“Longitudinal” is a direction running parallel to the maximum lineardimension of the article and includes directions within ±45° of thelongitudinal direction.

The “lateral” or “transverse” direction is orthogonal to thelongitudinal direction.

The “Z-direction” is orthogonal to both the longitudinal and transversedirections.

The “x-y plane refers to the plane congruent with the longitudinal andtransverse directions.

The term “disposable” is used herein to describe absorbent articles thatgenerally are not intended to be laundered or otherwise restored orreused as an absorbent article (i.e., they are intended to be discardedafter a single use and, preferably, to be recycled, composted orotherwise disposed of in an environmentally compatible manner).

As used herein, the term “disposed” is used to mean that an element(s)is formed (joined and positioned) in a particular place or position as aunitary structure with other elements or as a separate element joined toanother element.

As used herein, the term “joined” encompasses configurations whereby anelement is directly secured to another element by affixing the elementdirectly to the other element, and configurations whereby an element isindirectly secured to another element by affixing the element tointermediate member(s) which in turn are affixed to the other element.The term “joined” further encompasses configurations where two elementsare formed from a single material.

A “unitary” absorbent article refers to absorbent articles which areformed of separate parts united together to form a coordinated entity sothat they do not require separate manipulative parts like a separateholder and liner.

As used herein, the term “diaper” refers to an absorbent articlegenerally worn by infants and incontinent persons about the lower torso.

The terms “water-permeable” and “water-impermeable” refer to thepenetrability of materials in the context of the intended usage ofdisposable absorbent articles. Specifically, the term “water-permeable”refers to a layer or a layered structure having pores, openings, and/orinterconnected void spaces that permit liquid water to enter or passthrough its thickness in the under typical use conditions (for examplewithout the need to apply a significant or unrepresentative forcingpressure). Conversely, the term “water-impermeable” refers to a layer ora layered structure through the thickness of which liquid water cannotpass in the absence of a forcing pressure (for example, under typical inuse conditions). A layer or a layered structure that iswater-impermeable according to this definition may be permeable to watervapor, i.e., may be “vapor-permeable”. As is well known in the art, acommon method for measuring the permeability to water of the materialstypically used in absorbent articles is a hydrostatic pressure test,also called a hydrostatic head test or simply a “hydrohead” test.Suitable well known compendial methods for hydrohead testing areapproved by INDA (formerly the International Nonwovens and DisposablesAssociation, now The Association of the Nonwoven Fabrics Industry) andEDANA (European Disposables And Nonwovens Association).

As used herein, the term “barrier cuff” refers to an elasticized flapwhich stands substantially upright, more preferably inwardly towards thelongitudinal centerline, within the crotch region. Typically, saidbarrier cuff envelopes/contains at least one elastic that is connectedprimarily at its opposing ends to the diaper (e.g., drawstring techniquefor better fit).

As used herein, the term “gasketing cuff” refers to an elasticized flapwhich does not stand substantially upright, or which more preferably isdisposed outwardly towards the longitudinal side edges of the diaper,within the crotch region. Typically, said gasketing cuffenvelopes/contains at least one elastic that is connected substantiallythroughout its length to the diaper (e.g., multiple bonds along lengthof elastic to create gathers).

FIG. 1 is a plan view of an exemplary, non-limiting embodiment of adiaper 20 of the present invention in its flat-out, uncontracted state(i.e., without elastic induced contraction) with portions of thestructure being cut away to more clearly show the underlying structureof the diaper 20 and with the portion of the diaper 20 which contactsthe wearer facing the viewer. The diaper 20 is shown in FIG. 1 to have afront waist region 22, a back waist region 24, a crotch region 26, and aperiphery 28 which is defined by the outer edges of the diaper in whichthe longitudinal edges are designated 30 and the end edges aredesignated 32. The diaper 20 additionally has a lateral axis orcenterline which is designated 34 and a longitudinal axis or centerlinewhich is designated 36.

A main body or chassis of the diaper has an outer covering includingliquid permeable topsheet 38, a top surface of the topsheet 38 beingdesignated 40; a liquid impermeable backsheet 42; and an absorbentassembly or core 44 having side edges 46 and comprising an absorbentlayer 48 and first and second tissue layers (or nonwoven wrappinglayers) 50 and 52, respectively, encased between the topsheet 38 andbacksheet 42. For unitary absorbent articles, the chassis 23 comprisesthe main structure of the diaper with other features added to form thecomposite diaper structure. For example, the diaper 20 may include apair of tape-tab fasteners 54; gasketing cuffs 56 each comprising sideflap 58 and flap elastic members 60; barrier cuffs 62 each having aproximal edge 64, a distal edge 66, an inboard surface 68, an outboardsurface 70, a first end 72 and a second end 74; and spacing means 76,such as spacing elastic member 77 for spacing the distal edge 66 awayfrom the topsheet top surface 40. The diaper 20 additionally includesattachment means 78 such as an adhesive glue bead 79 for securing closedthe first and second ends 72 and 74 of each barrier cuff 62. Otherattachment means 78 may include thermal bonds, mechanical bonds,pressure bonds, ultrasonic bonds, combinations of these, or the like.The areas in which the attachment means 78 are disposed are designatedthe front closure zone 80 and the back closure zone 82. While thetopsheet 38, the backsheet 42, and the absorbent core 44 may beassembled in a variety of well-known configurations, preferred diaperconfigurations are described generally in U.S. Pat. No. 3,860,003entitled “Contractible Side Portions for Disposable Diaper” issued toKenneth B. Buell on Jan. 14, 1975; U.S. Pat. No. 5,151,092 issued toBuell on Sep. 9, 1992; and U.S. Pat. No. 5,221,274 issued to Buell onJune 22, 1993; and U.S. Pat. No. 5,554,145 entitled “Absorbent ArticleWith Multiple Zone Structural Elastic-Like Film Web Extensible WaistFeature” issued to Roe et al. on Sep. 10, 1996; U.S. Pat. No. 5,569,234entitled “Disposable Pull-On Pant” issued to Buell et al. on Oct. 29,1996; U.S. Pat. No. 5,580,411 entitled “Zero Scrap Method ForManufacturing Side Panels For Absorbent Articles” issued to Nease, etal. on Dec. 3, 1996; and U.S. Pat. No. 6,004,306 entitled “AbsorbentArticle With Multi-Directional Extensible Side Panels” issued to Robleset al. on Dec. 21, 1999.

FIG. 1 shows an embodiment of the diaper 20 in which the topsheet 38 andthe backsheet 42 are coextensive and have length and width dimensionsgenerally larger than those of the absorbent core 44. The topsheet 38 isassociated with and superposed on the backsheet 42 thereby to form theperiphery 28 of the diaper 20. The periphery 28 defines the outerperimeter or, in other words, the edges of the diaper 20. The periphery28 comprises the end edges 32 and the longitudinal edges 30. Thetopsheet 38 need not be generally coextensive with the backsheet 42. Forexample, the topsheet 38 could be more narrow than the backsheet 42 ormore wide than the backsheet 42. The overall diaper structure could be ashaped structure with a narrowing in the crotch region 26 as shown inFIG. 1. In other embodiments (such as shown in FIG. 15), separate “ear”or side panels 154 could be attached to a generally rectangular (oranother shaped) main body portion 223. Such ear panels could be integralwith the main portion or be separately attached. They could be madeelastically stretchable, if desired. Fasteners, such as fasteners 54 maybe attached to or integral with such ear panels if they are included.The topsheet 38 could be bonded to the barrier cuffs 62 and thistopsheet barrier cuff combination could be bonded to the backsheet.

The diaper 20 has front and back waist regions 22 and 24 extendingrespectively from the end edges 32 of the diaper periphery 28 toward thelateral axis 34 of the diaper 20 a distance from about ¼ to about ⅓ thelength of the diaper 20. The waist regions comprise those portions ofthe diaper 20 which, when worn, encircle the waist of the wearer. Thecrotch region 26 is that portion of the diaper 20 between the waistregions 22 and 24, and comprises that portion of the diaper 20 which,when worn, is positioned between the legs of the wearer and covers thelower torso of the wearer.

FIG. 2 is a fragmentary sectional view taken along line 2-2 of FIG. 1and depicts the diaper construction in the back waist region 24 of thediaper 20. (It should be understood that, in the illustrated embodiment,the diaper construction in the front waist region 22 is identical to theconstruction in the back waist region 24.) The absorbent core comprisesthe absorbent layer 48 that is shown as being completely enveloped bythe first and second tissue layers (or nonwoven layers) 50 and 52. Theabsorbent core 44 is disposed between the topsheet 38 and the backsheet42; both the topsheet 38 and the backsheet 42 extend beyond the sideedge 46 of the absorbent core 44 to define the side flap 58. Thejuxtaposed areas of the topsheet 38 and the backsheet 42 are securedtogether such as by adhesive 88. In the illustrated embodiment, the flapelastic members 60 do not extend into the waist region so that thegasketing cuff 56 is not formed in this region. The barrier cuff 62 isshown as being a separate element secured to the topsheet 38; theproximal edge 64 being formed by securing the element to the topsheet 38by attachment means 92. Such attachment means could be any suitableattachment mechanism such as adhesive, mechanical bonding, thermalbonding, pressure bonding, ultrasonic bonding, combinations of these, orthe like. The inboard surface 68 of the barrier cuff 62 is secured tothe topsheet top surface 50 by attachment 78 such as the glue bead 79.This attachment 78 could also be accomplished through a variety ofmechanisms such as adhesive, mechanical bonding, thermal bonding,pressure bonding, ultrasonic bonding, or the like. Therefore, the distaledge 66 is closed (i.e., it is not spaced away from the topsheet topsurface 40). It should be noted that the spacing elastic member 77 isnot disposed in this region because the distal edge 66 is not designedto be spaced away from the topsheet top surface 40 in the waist regions.Therefore, the barrier cuff 62 is neither open nor ready to constrainthe flow of body exudates in this region.

FIG. 3 is a fragmentary sectional view taken along line 3-3 of FIG. 1and depicts the diaper construction in the crotch region 26 of thediaper 20 as it is shaped before being applied to the wearer (i.e., thediaper 20 is subjected to elastic contraction). The absorbent core 44comprises the absorbent layer 48 that is shown as being completelyenveloped by the first and second tissue or nonwoven layers 50, 52. Theabsorbent core 44 is disposed between the topsheet 38 and the backsheet42; both the topsheet 38 and the backsheet 42 extend beyond the sideedge 46 of the absorbent core 44 to define the side flap 58. Thejuxtaposed areas of the topsheet 38 and the backsheet 42 are securedtogether by adhesive 88.

The topsheet 38 and the backsheet 42 also enclose the flap elasticmembers 60 adjacent the longitudinal edge 30 in the periphery 28. Theflap elastic members 60 are secured in the topsheet-backsheet formedside flap 58 by elastic attachment means 90. The elasticallycontractible gasketing cuff 56 is thereby formed by the side flap 58 byelastic attachment means 90. The barrier cuff 62 is shown as beingformed by securing an element to the topsheet 38 between the flapelastic members 60 and the side edge 46 of the absorbent core 44. Theproximal edge 64 of the barrier cuff 62 is formed by securing thebarrier cuff element to the topsheet 38 by attachment means 92. Thespacing elastic members 77 are enclosed in a tunnel that is formed whenan end of the barrier cuff element is folded back on itself; the spacingelastic members 77 being secured in the barrier cuff 62 by elasticattachment means 94. The distal edge 66 of the barrier cuff is spacedaway from the topsheet top surface 40 by the elastic gathering action ofthe spacing elastic members 77; a channel 96 thereby being formed by atleast the proximal edge 64, the distal edge 66 and the inboard surface68 of the barrier cuff 62. The channel 96 is shown as being ready torestrain, contain, and hold body exudates until the diaper 20 is removedfrom the wearer.

The topsheet 38 may be fully or partially elasticized or may beforeshortened so as to provide a void space between the topsheet 38 andthe core 44. Exemplary structures including elasticized or foreshortenedtopsheets are described in more detail in U.S. Pat. No. 4,892,536 issuedto DesMarais et al. on Jan. 9, 1990 entitled “Absorbent Article HavingElastic Strands”; U.S. Pat. No. 4,990,147 issued to Freeland on Feb. 5,1991 entitled “Absorbent Article With Elastic Liner For Waste MaterialIsolation”; U.S. Pat. No. 5,037,416 issued to Allen et al. on Aug. 6,1991 entitled “Disposable Absorbent Article Having ElasticallyExtensible Topsheet”; and U.S. Pat. No. 5,269,775 issued to Freeland etal. on Dec. 14, 1993 entitled “Trisection Topsheets For DisposableAbsorbent Articles and Disposable Absorbent Articles Having SuchTrisection Topsheets.”

The absorbent core 44 may comprise any absorbent material that isgenerally compressible, conformable, non-irritating to the wearer'sskin, and capable of absorbing and retaining liquids such as urine andother certain body exudates. The absorbent core 44 may include first andsecond opposed faces and comprise an absorbent layer 48 and first andsecond tissue or nonwoven layers 50, 52. The first and second tissue ornonwoven layers 50, 52 may overlay the major surfaces of the absorbentlayer 48 to form the first and second opposed faces of the absorbentcore. The absorbent core 44 may comprise a wide variety ofliquid-absorbent materials commonly used in disposable diapers and otherabsorbent articles such as comminuted wood pulp, which is generallyreferred to as air felt. Examples of other suitable absorbent materialsinclude creped cellulose wadding; melt blown polymers, includingco-form; chemically stiffened, modified or cross-linked cellulosicfibers; tissue, including tissue wraps and tissue laminates; absorbentfoams; absorbent sponges; superabsorbent polymers; absorbent gellingmaterials; or any other known absorbent material or combinations ofmaterials. The absorbent core 44 may be comprised of multiple layersincluding an acquisition and/or distribution layer. Such an acquisitionor distribution layer may be coextensive with the remaining layers ofthe core, or may be or different dimensions or positioning. Theabsorbent core 44 may be made predominately of superabsorbent materialwithout the addition of absorbent fibers (such as a “airfelt free”core). Such an airfelt free core may comprise predominatelysuperabsorbent particles, and a microfiber glue.

The core structure may also include wetness sensation members or acombination of wetness sensation member (or members) and an acquisitionlayer or layers. Any or all of the core structures (such as the optionalwetness sensation member(s) or acquisition layer(s)) may be tinted orhighlighted for visibility if desired.

Exemplary absorbent structures for use as the absorbent assemblies aredescribed in U.S. Pat. No. 4,610,678 entitled “High-Density AbsorbentStructures” issued to Weisman et al. on Sep. 9, 1986; U.S. Pat. No.4,673,402 entitled “Absorbent Articles With Dual-Layered Cores” issuedto Weisman et al. on Jun. 16, 1987; U.S. Pat. No. 4,834,735, entitled“High Density Absorbent Members Having Lower Density and Lower BasisWeight Acquisition Zones”, issued to Alemany et al. on May 30, 1989;U.S. Pat. No. 4,888,231 entitled “Absorbent Core Having A Dusting Layer”issued to Angstadt on Dec. 19, 1989; U.S. Pat. No. 5,137,537 entitled“Absorbent Structure Containing Individualized, Polycarboxylic AcidCrosslinked Wood Pulp Cellulose Fibers” which issued to Herron et al. onAug. 11, 1992; U.S. Pat. No. 5,147,345 entitled “High EfficiencyAbsorbent Articles For Incontinence Management” issued to Young et al.on Sep. 15, 1992; U.S. Pat. No. 5,342,338 entitled “Disposable AbsorbentArticle For Low-Viscosity Fecal Material” issued to Roe on Aug. 30,1994; U.S. Pat. No. 5,260,345 entitled “Absorbent Foam Materials ForAqueous Body Fluids and Absorbent Articles Containing Such Materials”issued to DesMarais et al. on Nov. 9, 1993; U.S. Pat. No. 5,387,207entitled “Thin-Until-Wet Absorbent Foam Materials For Aqueous BodyFluids And Process For Making Same” issued to Dyer et al. on Feb. 7,1995; U.S. Pat. No. 5,397,316 entitled “Slitted Absorbent Members ForAqueous Body Fluids Formed Of Expandable Absorbent Materials” issued toLaVon et al. on Mar. 14, 1995; U.S. Pat. No. 5,625,222 entitled“Absorbent Foam Materials For Aqueous Fluids Made From high InternalPhase Emulsions Having Very High Water-To-Oil Ratios” issued toDesMarais et al. on Jul. 22, 1997; and U.S. Patent application number2004/0162536 published on Aug. 19, 2004 entitled “Comfortable Diaper.”

The backsheet 42 is generally that portion of the diaper 20 positionedadjacent the garment-facing surface of the absorbent core 44. Backsheet42 prevents the exudates absorbed and contained therein from soilingarticles that may contact the diaper 20, such as bed sheets andundergarments. In preferred embodiments, the backsheet 26 issubstantially impermeable to liquids (e.g., urine) and comprises alaminate of a nonwoven and a thin plastic film such as a thermoplasticfilm having a thickness of about 0.012 mm (0.5 mil) to about 0.051 mm(2.0 mils). Suitable backsheet films include those manufactured byTredegar Industries Inc. of Terre Haute, IN and sold under the tradenames X15306, X10962, and X10964. Other suitable backsheet materials mayinclude breathable materials that permit vapors to escape from thediaper 20 while still preventing exudates from passing through thebacksheet 42. Exemplary breathable materials may include materials suchas woven webs, nonwoven webs, composite materials such as film-coatednonwoven webs, and microporous films such as manufactured by MitsuiToatsu Co., of Japan under the designation ESPOIR NO and by EXXONChemical Co., of Bay City, Tex., under the designation EXXAIRE. Suitablebreathable composite materials comprising polymer blends are availablefrom Clopay Corporation, Cincinnati, Ohio under the name HYTREL blendP18-3097. Such breathable composite materials are described in greaterdetail in PCT Application No. WO 95/16746, published on Jun. 22, 1995 inthe name of E. I. DuPont and U.S. Pat. No. 5,865,823 issued to Curro onFeb. 2, 1999. Other breathable backsheets including nonwoven webs andapertured formed films are described in U.S. Pat. No. 5,571,096 issuedto Dobrin et al. on Nov. 5, 1996. An exemplary, suitable backsheet isdisclosed in U.S. Pat. No. 6,107,537 entitled “Disposable absorbentarticles providing a skin condition benefit” issued to Elder et al onAug. 22, 2000. Other suitable materials and/or manufacturing techniquesmay be used to provide a suitable backsheet 42 including, but notlimited to, surface treatments, particular film selections andprocessing, particular filament selections and processing, etc.

Backsheet 42 may also consist of more than one layer, as exampled inFIG. 1, wherein a backsheet outer layer (often referred to as thebacksheet) may be made of a soft, non-woven material and a backsheetinner layer may be made of a substantially impermeable film. Adhesive orany other suitable material or method may be used to join layers andtogether. While a variety of backsheet configurations are contemplatedherein, it would be obvious to those skilled in the art that variousother changes and modifications can be made without departing from thespirit and scope of the invention.

The diaper 20 may also include a fastening system. The fastening systempreferably maintains the front waist region 22 and the back waist region24 in a configuration so as to provide lateral tensions about thecircumference of the diaper 20 to hold the diaper 20 on the wearer. Thefastening system may comprise a fastener such as tape tabs 54, which maybe applied to the back waist region 24 of the diaper 20. Alternatively,the fastening system may employ adhesive fasteners, cohesive fasteners,selective adhesive fasteners, mechanical fasteners, hook and loopfastening components, interlocking fasteners such as tabs & slots,buckles, buttons, snaps, macro-fasteners, and/or hermaphroditicfastening components, and combinations of any of these although anyother known fastening means are generally acceptable. Some exemplarysurface fastening systems are disclosed in U.S. Pat. No. 3,848,594entitled “Tape Fastening System for Disposable Diaper” issued to Buellon Nov. 19, 1974; U.S. Pat. No. B1 4,662,875 entitled “AbsorbentArticle” issued to Hirotsu et al. on May 5, 1987; U.S. Pat. No.4,846,815 entitled “Disposable Diaper Having An Improved FasteningDevice” issued to Scripps on Jul. 11, 1989; U.S. Pat. No. 4,894,060entitled “Disposable Diaper With Improved Hook Fastener Portion” issuedto Nestegard on Jan. 16, 1990; U.S. Pat. No. 4,946,527 entitled“Pressure-Sensitive Adhesive Fastener And Method of Making Same” issuedto Battrell on Aug. 7, 1990; the herein before referenced U.S. Pat. No.5,151,092 issued to Buell on Sep. 9, 1992; and U.S. Pat. No. 5,221,274issued to Buell on Jun. 22, 1993. An exemplary interlocking fasteningsystem is disclosed in U.S. Pat. No. 6,432,098 entitled “AbsorbentArticle Fastening Device” in the names of Kline et al. issued on Aug.13, 2002. The fastening system 55 may also provide a means for holdingthe article in a disposal configuration as disclosed in U.S. Pat. No.4,963,140 issued to Robertson et al. on Oct. 16, 1990. The fasteningsystem may also include primary and secondary fastening systems, asdisclosed in U.S. Pat. No. 4,699,622 entitled “Disposable Diaper HavingAn Improved Side Closure” issued to Toussant et al. on October 13, 1987.to reduce shifting of overlapped portions or to improve fit as disclosedin U.S. Pat. No. 5,242,436 entitled “Absorbent Article With FasteningSystem Providing Dynamic Elasticized Waistband Fit” issued to Weil etal. on Sep. 7, 1993; U.S. Pat. No. 5,499,978 entitled “Absorbent ArticleWith Dynamic Elastic Waist Feature Having A Predisposed ResilientFlexural Hinge” issued to Buell et al. on Mar. 19, 1996; U.S. Pat. No.5,507,736 entitled “Absorbent Article With Dynamic Elastic Waist FeatureComprising An Expansive Tummy Panel” issued to Clear et al. on Apr. 16,1996; U.S. Pat. No. 5,591,152 entitled “Absorbent Article With DynamicElastic Waist Feature Having A Predisposed Resilient Flexural Hinge”issued to Buell et al. on Jan. 7, 1997.

In alternative embodiments, the article may be preformed by themanufacturer to create a pant. The term “pant”, as used herein, refersto disposable garments having a waist opening and leg openings designedfor infant or adult wearers. A pant may be placed in position on thewearer by inserting the wearer's legs into the leg openings and slidingthe pant into position about the wearer's lower torso. A pant may bepreformed by any suitable technique including, but not limited to,joining together portions of the article using refastenable and/ornon-refastenable bonds (e.g., seam, weld, adhesive, cohesive bond,fastener, etc.). While the term “pant” is used herein, pants are alsocommonly referred to as “closed diapers”, “prefastened diapers”,“pull-on diapers”, “training pants” and “diaper-pants”. Suitable pantsare disclosed in U.S. Pat. No. 5,246,433, issued to Hasse, et al. onSep. 21, 1993; U.S. Pat. No. 5,569,234, issued to Buell et al. on Oct.29, 1996; U.S. Pat. No. 6,120,487, issued to Ashton on Sep. 19, 2000;U.S. Pat. No. 6,120,489, issued to Johnson et al. on Sep. 19, 2000; U.S.Pat. No. 4,940,464, issued to Van Gompel et al. on Jul. 10, 1990; U.S.Pat. No. 5,092,861, issued to Nomura et al. on Mar. 3, 1992; U.S. PatentApplication No. 2003/0233082, entitled “Highly Flexible And LowDeformation Fastening Device”, Published on Dec. 18, 2003; U.S. Pat. No.5,897,545, issued to Kline et al. on Apr. 27, 1999; U.S. Pat. No.5,957,908, issued to Kline et al on Sep. 28, 1999.

The diaper 20 may also include such other features as are known in theart including graphics, front and rear ear panels, waist cap features,elastics and the like to provide better fit, containment and aestheticcharacteristics. Such additional features are well known in the art andare described in U.S. Pat. No. 3,860,003; and U.S. Pat. No. 5,151,092.

In the embodiment illustrated in FIG. 1, each barrier cuff 62 is aflexible member having a proximal edge 64, a distal edge 66, an inboardsurface 68, and an outboard surface 70. As used herein, the termflexible refers to materials which are compliant and will readilyconform to the general shape and contours of the body. In addition, ifthe spacing means 76 comprise spacing elastic members 77, the barriercuff 62 should be contractible so that the distal edge 66 may besufficiently spaced away from the topsheet top surface 40 so that achannel 96 is formed to restrain, contain, and hold body exudates withinthe article. The barrier cuff 62 may be manufactured from a wide varietyof materials such as polypropylene, polyester, rayon, nylon, foams,plastic films, formed films, and elastic films. The barrier cuff 62 mayalso include absorbent materials including absorbent glue, if desired. Anumber of manufacturing techniques may be used to manufacture thebarrier cuff. For example, the barrier cuff 62 may be woven, non-woven,spunbonded, carded, or the like.

As shown in FIGS. 1 and 3, the barrier cuff 62, and more particularlythe proximal edge 64, is disposed inboard of and preferably adjacent tothe gasketing cuff 56. The term “inboard” is defined as the directiontoward the centerline (34 or 36, respectively) of the diaper that isparallel to the respective edge of the diaper 20 along which theparticular gasketing cuff 56 is disposed. The barrier cuff 62 isdisposed inboard of the gasketing cuff 56 so that exudates, especiallyloose fecal material which is not easily absorbed and tends to floatalong the topsheet top surface 40, will contact the barrier cuff 62before it can contact the gasketing cuff 56. The barrier cuff 62 isdisposed adjacent the gasketing cuff 56 to provide a more effective dualrestraint against the flow of body exudates.

The proximal edge 64 and the distal edge 66 are in spaced relation toeach other and define the width of the barrier cuff 62. The proximal anddistal edges 64, 66 may be in a parallel, non-parallel, rectilinear, orcurvilinear relationship. In addition, the barrier cuff 62 may have avariety of different cross-sectional areas including circular, square,rectangular, or any other shape such as shown in FIG. 3. The proximaledge 64 may be spaced from the distal edge 66 in a parallel andrectilinear relationship to provide a barrier cuff 62 having uniformwidth. Each barrier cuff 62 may have a width of at least 5 mm and may beapproximately 10-50 mm. The barrier cuff 62 may be formed from a foldedstructure in which portions of the cuff material may be folded back uponitself at one or more locations. In such constructions the distal andproximal edges usually are the most inboard and outboard locations ofthe cuff material with regard to any folding back of such cuff material.

Each barrier cuff 62 may be joined to the topsheet 38. As noted above,the term “joined” includes any means for affixing the barrier cuff 62 tothe diaper 20, and includes embodiments wherein the barrier cuff 62 is aseparate element having a proximal edge 64 directly or indirectlyattached to the topsheet 38 or embodiments wherein the barrier cuff 62is made from the same element or material as the topsheet 38 so that theproximal edge 64 is a continuous and undivided element of the topsheet42. The barrier cuff 62 may alternatively be joined to the backsheet 42,the absorbent core 44, the topsheet 38, or any combination of these orother elements of the diaper 20. If provided integrally with thetopsheet 38, the barrier cuff 62 may be formed by a single strip ofmaterial which is secured to the topsheet 38 by attachment means 92, thedistal edge 66 being formed by folding an end of the material back uponitself. The barrier cuff 62 can also be formed out of the same materialas the topsheet 38 or the backsheet 42 or by the combination of thetopsheet and backsheet materials. Additionally, the barrier cuff 62 maybe formed out of a portion of the core assembly.

The distal edge 66 may be disposed inboard of the proximal edge 64 topresent a more effective barrier against the flow of exudates. Thedistal edges 66 are maintained inboard of the proximal edges 64 byattachment means 78 (such as adhesive, thermal bonds, pressure bonds,ultrasonic bonds, etc.) so as to obviate their inversion. The distaledge 66 may be unsecured to any other element in at least the crotchregion 26 of the diaper 20 so that it may be spaced away from the topsurface 40 of the topsheet 38. The distal edge 66 may be spaced from thetopsheet top surface 40 so that the barrier cuff 62 may form a channel96 to enhance containment of the article. As used herein, “spaced”includes embodiments wherein the distal edges 66 may assume one or morepositions relative to the topsheet top surface 40 including at sometimes assuming a position adjacent the topsheet top surface. Thedistance between the distal edge 66 to the topsheet top surface 40 ismeasured along a line drawn from the distal edge 66 to the closest partof the topsheet 38 when the distal edge 66 is positioned so as to bespaced away from the topsheet as far as possible (i.e., in theelastically contracted position). The distal edge 66 may be spaced awayfrom the topsheet 38 by a height of at least 2 mm, and more may bespaced from about 5 mm to about 50 mm.

The channel 96 is formed at least along the proximal and distal edges64, 66 and the inboard surface 68 of the barrier cuff 62. The channel 96forms a barrier to the flow of exudates as they tend to move or floatacross the topsheet 38. Thus, the channel 96 holds and contains exudatesuntil the diaper 20 can be removed. The barrier cuffs 62 may be providedwith absorbent means and/or may be rendered liquid impermeable asdisclosed in U.S. Pat. No. 4,743,246 which issued to Lawson on May 10,1988.

The spacing means 76 for spacing the distal edge 66 away from thetopsheet top surface 40 is any member which gathers, contracts,stiffens, shortens, or otherwise acts on the barrier cuff 62 so as tocause a channel 96 to be formed along the barrier cuff 62 to provide aconstraint against the leakage of exudates. As shown in FIG. 1, thespacing means 76 may comprise a spacing elastic member 77 securedadjacent the distal edge 66 inside the barrier cuff 62. The spacingelastic member 77 is preferably secured to the barrier cuff 62 in anelastically contractible condition so that in a normally unrestrainedconfiguration, the spacing elastic member 77 effectively contracts orgathers the barrier cuff 62. The spacing elastic member 77 can besecured to the barrier cuff 62 in an elastically contractible conditionin at least two ways as is discussed in the above-referenced U.S. Pat.No. 3,860,003 issued to K. B. Buell. In addition, the length of thespacing elastic member 77 in general is dictated by the diaper design.In the embodiment illustrated in FIG. 1, the spacing elastic member 77extends essentially the entire length of the barrier cuff 62 in thecrotch region 26, although other lengths are cognizable. Additionaldetails and alternatives for the spacing means are discussed in theabove-referenced U.S. Pat. No. 4,743,246 to Lawson.

The attachment means 78 for securing end portions 72 and 74 of thebarrier cuff 62 closed are shown in FIGS. 1 and 2. The attachment means78 provide a more comfortable fit for the wearer and obviate inversionof the distal edges 66 of the barrier cuff 62 during application anduse. Inversion is generally defined as the inboard disposed distal edge66 turning outwardly when the diaper 20 is applied to the wearer. In theembodiment illustrated at FIGS. 1 and 2, such adhesive means 78 aredisposed in the front waist region 22 and the back waist region 24 ofthe diaper in the front closure zone 80 and the back closure zone 82,respectively. Except as noted below, the remaining portions of thebarrier cuff 62 are not secured closed so that the distal edges 66 aregenerally left freely openable.

FIG. 4 is a sectional view of the diaper 20 in its elasticallycontracted position prior to being placed on the wearer. The topsheet 38is shown as the body contacting surface of the diaper 20, the backsheet42 being disposed away from the body of the wearer. The gasketing cuffs56 are shown to be gathered or contracted. The diaper 20 is shown ashaving two barrier cuffs 62 extending adjacent to and inboard of thegasketing cuffs 56. The distal edges 66 are shown to be gathered andcontracted by the spacing elastic members (not shown) in the crotchregion 26 so as to provide a longitudinally extending channel 96 alongthe diaper 20. In addition, the ends 72, 74 of the barrier cuff aresecured closed in the front and back closure zones 80, 82, respectively,so as to provide comfort for the wearer, to obviate inversion of thebarrier cuffs, and for ease of application of the diaper.

One way of applying the diaper 20 is by positioning the back waistregion 24 under the wearer's back, and drawing the remainder of thediaper 20 between the wearer's legs so that the front waist region 22 ispositioned across the front of the wearer. The ends of the tape-tabfasteners 54 are then secured to outwardly facing areas of the diaper20. In this manner the barrier cuffs 62 should be disposed in the crotchregion of the wearer and should provide the dispositions and functionsdescribed hereinbefore. The diaper 20 may also be applied with thewearer standing up, if desired. Once applied, the distal edges 66 of thebarrier cuffs 62 extend through the groin area and diverge upwardlyalong both of the buttocks of the wearer. Neither of the barrier cuffs62 encircles the thighs of the wearer. However, the gasketing cuffs 56will encircle the thighs and create a gasketing action against thethighs. The ends of the barrier cuff are secured to the topsheet 38 toobviate the inversion of the barrier cuffs, for comfort to the wearerduring application and use, and for ease of application.

FIG. 5 is a fragmentary coronal view showing a section of the diaper 20of FIG. 1 in place on a wearer. A coronal view is a frontal plane thatpasses through the long axis of the body. As shown in FIG. 5, thegasketing cuffs 56 ride down on the legs and encircle the thighs of thewearer. The barrier cuffs 62 ride up on the legs and run through thecrotch region and diverge upwardly over both the buttocks of the wearer.The distal edges 66 are spaced away from the topsheet top surface 40 andlie against the perineum of the wearer. The barrier cuffs 62 are,therefore, pushed snugly against the perineum of the wearer in thecrotch region 26 of the diaper 20. The size of the channel 96 isenhanced by the resiliency of the absorbent core 44 because the coretends to push itself away from the perineum. This results in the diaper20 having channels 96 extending along the crotch region of the wearer.Therefore, body exudates are restrained from penetrating beyond thebarrier cuffs 62 because the channels 96 form a barrier to the flow ofexudates. As loose fecal material is discharged onto the topsheet 38,the material flows or floats along the topsheet top surface 40(hereinafter referred to as “surface material”). The surface materialmoves from the point of discharge toward the longitudinal edges 30 andwill contact the barrier cuffs 62 along the inboard surfaces 68. Innormal use, gravitational forces will tend to cause the surface materialto collect in the channel 96 formed by the standing barrier cuff 62; thematerial being held in the channels 96 until the diaper 20 can beremoved. Containment is achieved because the surface material would haveto flow up the channel 96, which direction is substantially directlyagainst the force of gravity when the wearer is in an upright position,in order to penetrate and flow over the distal edges 66 of the barriercuffs 62. However, should such material flow beyond the barrier cuffs62, it is retarded from leaking out of the diaper 20 by the gasketingeffect achieved by the gasketing cuffs 56, as they draw and gather theside flaps 58 about the legs of the wearer, thereby providing a secondand independent effective barrier against leakage.

While barrier cuffs provide additional protection against leakage offloating exudates, it has been found that they may promote diaper sag,particularly in the front waist. Applicants have identified acontradiction between leakage protection and sustained fit in the priorart barrier cuffs. More specifically, and focusing on the front waistregion, for improved leakage protection it is desirable that the frontclosure zone 80 have a shorter length (such as 0 to 60 mm), while forprevention of waist sag it is desirable that the front closure zone 80be longer (such as 80 to 110 mm). In identifying this trade-off,applicants have noted that the contractible forces from typicalelasticized barrier cuffs are typically approximately 0.3 to 1.0 N,while the forces from a loaded absorbent core may be approximately 1.5to 3 N. Due to the points at which these forces are applied, however,applicants have found that the smaller forces applied by the unloadedelasticized cuff cause diaper sag while the larger forces created by aloaded absorbent core do not necessarily.

Without wishing to be bound by theory, it is believed that front waistdiaper sag will not occur if the following “no sag” criterium is met:

$f_{pull} \leq \frac{{f(c)} \cdot w \cdot T \cdot \left( {{{c_{fr} \cdot \cos}\; \overset{\prime}{\alpha}} + {\sin \; \overset{\prime}{\alpha}}} \right)}{r}$

-   -   where,    -   f_(pull) is the force pulling a portion of the diaper defined as        the “tension band” down (measured in cN),    -   f(c) is a dimensionless function of c, monotonic increasing, it        is small for c=0,    -   c is an anchoring point parameter that indicates where pulling        force is applied,    -   T is the tension in the diaper “tension band” (measured in cN),    -   w is the width of the diaper “tension band” (measured in cm),    -   r is the radius of curvature along the band plane (measured in        cm),    -   c_(fr) is the skin to diaper material coefficient of friction,        and    -   {acute over (α)} is the cone angle (measured in degrees).

FIGS. 6-8 illustrate the variables included in the no sag criterium.More specifically, FIG. 6 is a front view of a diaper on a wearer inwhich the tension band of the diaper is bounded by an upper edge 110 anda lower edge 112, which generally defines the area of the diaper placedin tension to maintain the diaper on the wearer. The width w of thetension band is also illustrated in FIGS. 6 and 7. The anchoringparameter variable c is related to the ratio of dimension Z measuredfrom the upper edge 110 to the point at which the pulling force isapplied to the width w of the tension band at the pulling force location(i.e., c=Z/w). The cone angle {acute over (α)} is illustrated in FIG. 7and is measured as the angle of the diaper with respect to a referenceline 114 extending normal to the plane of a centerline 116 of thetension band and a line tangential to babies surface. The radius ofcurvature r is the curvature of the tension band at the anchoring point,as illustrated in FIG. 8.

The relationships identified in the no sag criterium suggest severalalternatives for reducing sagging. For example, sagging is less likelyif the anchoring parameter c is large, which may be accomplished bylocating the anchoring point at the lower edge or below the tensionband. Sagging is also less likely if the radius of curvature r is small,which is accomplished by locating the anchoring point where the radiusof curvature is small, such as at the hips. The criterium furthersuggests that a large cone angle {acute over (α)}, will make saggingless likely, and may be accomplished by locating the anchoring pointwhere the cone angle is large, such as at the hips. Maximizing thetension band width w may be accomplished with long tapes. Therelationship of the variables may also suggest reducing sagging bylocating the upper edge of the tension band higher relative to thetackdown point of the barrier cuff. Also, locating the ears of thediaper high on the product (even above the waist) creates a higherlanding zone which may increase the likelihood of satisfying the no sagcriterium.

In view of the foregoing, applicants have found that an intermediatebond 120 applied to each barrier cuff 62 may reduce front waist saggingwhile allowing the barrier cuff 62 to effectively retain floatingexudates. As illustrated in FIG. 1, the intermediate bond 120 joins thebarrier cuff inboard surface 68 to an interior surface, such as thetopsheet top surface 40. The intermediate bond 120 is preferablylaterally offset from the front closure zone 80 so that it is locatedlaterally between the proximal and distal edges 64, 66 of the barriercuff 62. In the illustrated embodiment, the intermediate bond 120 islocated approximately midway between the proximal and distal edges 64,66. The intermediate bond 120 is further preferably longitudinallyoffset from the front closure zone 80 so that it is locatedlongitudinally between a respective front closure zone 80 and thelateral axis 34 of the diaper 20. Preferably, the intermediate bond 120is located within the front waist region 22.

In addition to the considerations identified by the no sag criterium,applicants have identified further considerations for minimizing diapersag. For example, anchoring the barrier cuff to a diaper element havinggreater stiffness, such as the absorbent core, or the landing zone alsoreduces sag. Referring to FIG. 9, a diaper 130 is illustrated having atopsheet 132, acquisition layer 134, absorbent core 136, and backsheet(not shown). Two barrier cuffs 138 are joined to the topsheet 132 andinclude a proximal edge 140 and a distal edge 142. Each proximal edge140 is attached to the topsheet 132 at an edge bond 144 running alongsubstantially the entire length of the barrier cuff. The distal edges142 are attached to the topsheet 132 at end bonds 146 located at opposedends of the distal edges 142. Intermediate bonds 148 are located atpoints laterally and longitudinally offset from the end bonds 146 yet atlocations which allow attachment to either or both of the acquisitionlayer 134 and the absorbent core 136. By anchoring the barrier cuffs 138to the stiffer diaper elements, diaper sag in the front waist region isreduced.

While the previous embodiments illustrate barrier cuffs having a distaledge located nearer the longitudinal centerline, an intermediate bond isalso effective for diapers having back-folded barrier cuffs where thedistal edge is located farther from the longitudinal centerline.Referring to FIGS. 10 and 11, a diaper 150 includes barrier cuffs 152having proximal edges 154 and distal edges 156. The distal edges 156 areanchored at end bonds 160. Intermediate bonds 162 are located laterallyand longitudinally offset from the end bonds 160. In the illustratedembodiment, the intermediate bonds 162 are aligned with the proximaledges 154 of the barrier cuffs 152 to minimize sagging in the frontwaist region.

The intermediate bond may be used with any known barrier cuff structure.For example, FIG. 12 illustrates a sectional view of an alternativebarrier cuff 662 formed by pleating the entire diaper structure (i.e.,the backsheet 42, the absorbent core 44, and the topsheet 38). Afterpleating the structure, the proximal edges 64 of the barrier cuff 662are secured together by adhesive 98. The barrier cuff 662 may havespacing means such as spacing elastic members 77 secured within thebarrier cuff 662 so elasticize the distal edges 66 so as to space thedistal edges 66 away from the top surface 40 of the topsheet 38.

FIG. 13 illustrates a further barrier cuff arrangement. A unitarybarrier cuff 762 is formed by U-folding or pleating the topsheet of thediaper 20. The topsheet is folded upon itself to form a distal edge 66;spacing elastic members 77 are secured within the tunnel formed in thedistal edge 66. The proximal edge 64 is secured by adhesive attachmentmeans 99 such as a glue bead made of hot melt adhesive.

FIG. 15 illustrates a barrier cuff 62 in which the end tackdown means 78is comprised of a series of discrete patterned bonds such as pressurebonds 179. The intermediate bond 120 in such an embodiment are discretefrom and not part of the general pattern formed by the bonds in the endtackdown area.

In addition to the single cuff barrier cuffs disclosed above, theintermediate bond may further be applied to dual cuff barrier cuffs.FIG. 14 illustrates one embodiment of a dual cuff barrier cuff 230 infragmentary sectional view taken in a crotch region of a diaper 220 asit is shaped before being applied to the wearer (i.e., the diaper issubjected to elastic contraction). Dual cuff 230 has a proximate end235, distal end 239 and regions therebetween identified as first cuff240 and second cuff 250. Dual cuff 230 may be constructed from acontinuous cuff material 233 that substantially envelopes the elasticsof first cuff 240 and second cuff 250. More specifically, first cuff 240has at least one elastic (although two elastics 242, 244 are shown) andsecond cuff 250 also has at least one elastic (although two elastics252, 254 are shown) that are enveloped within cuff material 233. In thisway, only a continuous cuff material 233 is used and manipulated duringthe construction of dual cuff 230, thus making easier the manufacturingof said dual cuff. Moreover, cuff material 233 need only beenclosed/bonded at a single location, as exampled by cuff bond 270, inorder to substantially envelope elastics 242, 244, 252, 254, thusproviding improved barrier properties by minimizing the number ofpotential leakable locations (e.g., bonding locations). Herein,“continuous cuff material” means a cuff material that is continuousalong a path beginning from the cuff end bond, along said cuff material,and ending at the same cuff end bond such that the dual cuff 230 issubstantially constructed of two layers of the materials, whether it isthe same or different materials. For example, the continuous cuffmaterial 233 may be constructed of a lesser-water-permeable material(e.g., spunbound material which is inexpensive) with amore-water-permeable material (e.g., meltblown material which is moreexpensive) placed inside said lesser-water-permeable material. Inanother example, cuff material 233 may be constructed of aspunbound-meltblown laminate. In yet another example, cuff material 233may be constructed of a series of various materials so long as they arecontinuous. In yet another example, cuff material 233 may be treated toincrease its hydrophobicity. Such hydrophobic treatments include, butare not limited to, the application of hydrophobic surface coating (asexampled in co-pending U.S. Patent Application Ser. No. 60/543,785,entitled “Hydrophobic Surface Coated Absorbent Articles And AssociatedMethods”, filed on Feb. 11, 2004) and flouro-treatment (as exampled inco-pending U.S. Patent Application No. 2004/0092902, entitled“Disposable Absorbent Articles With Masking Topsheet”, Published on May13, 2004). In yet another example, it may be desirable that dual cuff230 be connected to diaper 220 by way of a single bond (e.g., adhesive,ultrasonic; e.g., cuff bond 270 to topsheet 224).

Cuff bond 270 may extend substantially the entire longitudinal length ofdiaper 220. Cuff bond 270 may be adhesive, ultrasonic bonding,compression bonding, thermal bonding, combinations thereof, and anyother suitable bonding means known in the art which is appropriate forthe specific materials employed. Cuff bond 270 may also join dual cuff230 to topsheet 224. Lastly, an adhesive 276 having liquidimpermeability properties may be applied between the topsheet 224 andbacksheet 226 (or more specifically shown herein, backsheet inner layer227) to provide improved barrier properties. Adhesive 276 may be locatedjuxtaposed to intermediate bond 270; however, so long as adhesive 276helps to provide a containment of exudates, then its actual location maybe variable. Further, it may be desirable for the cuff material to onlybe bonded to itself by the cuff bond (i.e., no other bond similar tocuff bond 270 is used). Lastly, it may be desirable for both first cuff240 and second cuff 250 to be barrier cuffs.

Elastics 242, 244, 252, 254 may be operatively associated with theirrespective cuff by securing it within said cuff with an elasticattachment element 246. The elastic attachment element 246 should beflexible and of sufficient adhesiveness to hold elastics 242, 244, 252,254 in their stretched condition. Elastics 242, 244, 252, 254, having afirst and second end, may be secured to their respective cuff only neartheir ends or along their entire length. Elastic attachment element 246may be glue beads made of hot melt adhesive such as marketed by FindleyAdhesives Incorporated, Elmgrove, Wis., as Findley Adhesives 581.

Alternatively, elastic attachment element 246 may take the form of anultrasonic bond or heat/pressure seal. A more detailed description ofthe manner in which the elastic attachment element 246 may be positionedand secured to their respective cuff can be found in U.S. Pat. No.4,081, 301, issued to Buell on Mar. 28, 1978, and in U.S. Pat. No.4,253,461, issued to Strickland and Visscher on Mar. 3, 1981, both ofwhich are incorporated herein by reference. While elastics 242, 244 infirst cuff 240 and elastics 252, 254 in second cuff 250 were shown, itwould be obvious to those skilled in the art that one or more elasticsmay be used in each cuff without departing from the spirit and scope ofthe invention.

Elastics 242, 244, 252, 254 which have been found suitable are elasticstrands having a cross section of 0.18 mm by 1.5 mm and made fromnatural rubber as available from Easthampton Rubber Company of Stewart,Va., under the trademark L-1900 Rubber Compound. Other suitable elasticscan be made from natural rubber, such as elastic tape sold under thetrademark Fulflex 9411 by Fulflex Company of Middletown, R. I. Elasticstrands sold as Fullflex may have a cross section of about 0.18 mm by0.52 mm and be suitable. Elastics 242, 244, 252, 254 may also compriseany heat shrinkable elastic material as is well known in the art. Othersuitable elastic materials may comprise a wide variety of materials asare well known in the art include elastomeric films, polyurethane films,elastomeric foams, formed elastic scrim and synthetic elastomers (e.g.,Lycra™). In addition, elastics 242, 244, 252, 254 may take a multitudeof configurations. For example, the width may be varied; a single strandor several parallel or non-parallel strands of elastic material may beused; or a variety of shaped may be used including rectilinear andcurvilinear.

The dual cuff barrier cuff embodiments may also include pockets forreceiving and containing waste, spacers which provide voids for waste,barriers for limiting the movement of waste in the article, compartmentsor voids which accept and contain waste materials deposited in thediaper 220, and the like, or any combinations thereof. Examples ofpockets and spacers for use in absorbent products are described in U.S.Pat. No. 5,514,121 issued to Roe et al. on May 7, 1996, entitled “DiaperHaving Expulsive Spacer”; U.S. Pat. No. 5,171,236 issued to Dreier etal. on Dec. 15, 1992 entitled “Disposable Absorbent Article Having CoreSpacers”; U.S. Pat. No. 5,397,318 issued to Dreier on Mar. 14, 1995entitled “Absorbent Article Having A Pocket Cuff”; U.S. Pat. No.5,540,671 issued to Dreier on Jul. 30, 1996 entitled “Absorbent ArticleHaving A Pocket Cuff With An Apex”; PCT Application WO 93/25172published Dec. 3, 1993 entitled “Spacers For Use In Hygienic AbsorbentArticles And Disposable Absorbent Articles Having Such Spacer”; U.S.Pat. No. 5,306,266 entitled “Flexible Spacers For Use In DisposableAbsorbent Articles” issued to Freeland on Apr. 26, 1994; and U.S. Pat.No. 5,997,520 entitled “Disposable Absorbent Article With SelectivelyExpandable or Inflatable Component” issued to Ahr et al. on Dec. 7,1999. Examples of compartments or voids are disclosed in U.S. Pat.4,968,312 entitled “Disposable Fecal Compartmenting Diaper” issued toKhan on Nov. 6, 1990; U.S. Pat. No. 4,990,147 entitled “AbsorbentArticle With Elastic Liner For Waste Material Isolation” issued toFreeland on Feb. 5, 1991; U.S. Pat. No. 5,062,840, entitled “DisposableDiapers” issued to Holt et al on Nov. 5, 1991; and U.S. Pat. No.5,269,755 entitled “Trisection Topsheets For Disposable AbsorbentArticles And Disposable Absorbent Articles Having Such TrisectionTopsheets” issued to Freeland et al on Dec. 14, 1993. Examples ofsuitable transverse barriers are described in U.S. Pat. No. 5,554,142entitled “Absorbent Article Having Multiple Effective Height TransversePartition” issued Sep. 10, 1996 in the name of Dreier et al.; PCT PatentWO 94/14395 entitled “Absorbent Article Having An Upstanding TransversePartition” published Jul. 7, 1994 in the name of Freeland, et al.; andU.S. Pat. No. 5,653,703 Absorbent Article Having Angular UpstandingTransverse Partition issued Aug. 5, 1997 to Roe, et al. Examples ofother structures especially suitable for management of low viscosityfeces are disclosed in U.S. Pat. No. 5,941,864 issued to Roe et al. onAug. 24, 1999; U.S. Pat. Nos. 5,977,430 issued to Roe et al. on Nov. 2,1999 and 6,013,063 issued to Roe et al. on Jan. 11, 2000.

In addition, the present invention may be suitable for other diaperembodiments including those disclosed in U.S. Pat. No. 6,010,491 titled“Viscous Fluid Bodily Waste Management Article” issued Jan. 4, 2000;U.S. Pat. No. 5,873,870 titled “Fit And Sustained Fit Of A Diaper ViaChassis And Core Modifications” issued Febr. 23, 1999; U.S. Pat. No.5,897,545 titled “Elastomeric Side Panel for Use with ConvertibleAbsorbent Articles” issued Apr. 27, 1999; U.S. Pat. No. 5,904,673 titled“Absorbent Article With Structural Elastic-Like Film Web Waist Belt”issued May 18, 1999; U.S. Pat. No. 5,931,827 titled “Disposable Pull OnPant” issued Aug. 3, 1999; U.S. Pat. No. 5,977,430 titled “AbsorbentArticle With Macro-Particulate Storage Structure” issued Nov. 2, 1999and U.S. Pat. No. 6,004,306 titled “Absorbent Article WithMulti-Directional Extensible Side Panels” issued Dec. 21, 1999.

All documents cited are, in relevant part, incorporated herein byreference; the citation of any document is not to be construed as anadmission that it is prior art with respect to the present invention.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

1. An absorbent article comprising: an absorbent assembly having a frontwaist region, a back waist region, and a crotch region between the frontand back waist regions, an interior surface and an exterior surface, anda longitudinal axis and a lateral axis; an absorbent core disposedbetween the interior and exterior surfaces and having at least a portionextending into one of the waist regions; two laterally opposing,longitudinally extending barrier cuff strips associated with theinterior surface of the absorbent assembly, each barrier cuff striphaving longitudinally opposing front and back ends disposed in therespective waist regions and longitudinally extending, laterallyproximal and distal edges connecting the front and back ends, eachbarrier cuff strip being joined to the interior surface of the absorbentassembly along the proximal edge, each barrier cuff strip distal edgebeing attached to the interior surface of the absorbent assembly at endbonds located adjacent to the front and back ends of the barrier cuffstrip, wherein each end bond comprises a discrete bond site defining aclosure zone having a lateral width that is less than a lateral distancebetween the proximal and distal edges, and each barrier cuff stripincluding a longitudinally extending elastic gathering member attachedadjacent to the distal edge such that when allowed to relax, the elasticgathering member contracts and lifts the distal edge away from theinterior surface of the absorbent assembly; wherein each barrier cuffstrip is also joined to a portion of the absorbent assembly within oneof the waist regions at a discrete, intermediate bond, and wherein theentire intermediate bond is laterally offset from the width of therespective closure zone.
 2. The absorbent article of claim 1, whereinthe intermediate bond is located in the front waist region.
 3. Theabsorbent article of claim 1, wherein each intermediate bond is locatedlaterally between the proximal and distal edges and longitudinallybetween the respective end bond and the lateral axis.
 4. The absorbentarticle of claim 1, wherein the barrier cuff strips and the topsheet areformed from a same material piece.
 5. The absorbent article of claim 1,wherein the proximal edges of the barrier cuff strips are located nearerthe longitudinal axis than the distal edges of the barrier cuff strips.6. The absorbent article of claim 1, wherein the barrier cuff stripscomprise dual cuff barrier cuff strips.
 7. An absorbent articlecomprising: an absorbent assembly having a front waist region, a backwaist region, and a crotch region between the front and back waistregions, an interior surface and an exterior surface, and a longitudinalaxis and a lateral axis; two laterally opposing, longitudinallyextending barrier cuff strips associated with the interior surface ofthe absorbent assembly, each barrier cuff strip having longitudinallyopposing front and back ends disposed in the respective waist regionsand longitudinally extending, laterally proximal and distal edgesconnecting the front and back ends, wherein the proximal edges arelocated nearer the longitudinal axis than the distal edges, each barriercuff strip being joined to the interior surface of the absorbentassembly along the proximal edge, each barrier cuff strip distal edgebeing attached to the interior surface of the absorbent assembly at endbonds located adjacent to the front and back ends of the barrier cuffstrip, wherein each end bond comprises a discrete bond site defining aclosure zone having a lateral width that is less than a lateral distancebetween the proximal and distal edges, and each barrier cuff stripincluding a longitudinally extending elastic gathering member attachedadjacent to the distal edge such that when allowed to relax, the elasticgathering member contracts and lifts the distal edge away from theinterior surface of the absorbent assembly; wherein each barrier cuffstrip is also attached to the interior surface of the absorbent assemblyat a discrete, intermediate bond located laterally between the proximaland distal edges and longitudinally between the respective end bond andthe lateral axis within one of the waist regions, and wherein the entireintermediate bond is laterally offset from the width of the respectiveclosure zone.
 8. The absorbent article of claim 7, wherein theintermediate bond is located in the front waist region.
 9. The absorbentarticle of claim 7, wherein the barrier cuff strips are each constructedfrom a continuous cuff material and wherein barrier cuffs are connectedwith the topsheet.
 10. The absorbent article of claim 7, wherein thebarrier cuff strips comprise dual cuff barrier cuff strips.